5 Facts about Powder Metallurgy and Its Processes
Industries can usually choose from a wide range of materials in manufacturing parts and products they would need for their operations. Some of these materials are metals, plastics, timbres, and synthetic elements.
But one distinct material that more and more industries maximise today is metal powder. Metal powders come from solid metal materials that have been broken down into a fine, grainy powder. Some solid metals that are converted into metal powders are stainless steel, copper, iron, bronze, and brass. These metals are then integrated with other alloys so that metal powders can boast the characteristics and properties needed for specific applications.
When maximising metal powders in manufacturing, industries have to rely on powder metallurgy. This term covers various processes in which metal powders are prepared, mixed, blended, compacted, and sintered. Here are some notable facts about it and its processes.
1. Compaction is needed to generate a compact.
One of the processes involved in powder metallurgy is compaction. Compaction entails the application of pressure to metal powders and alloys so they can retain the shape of the mould. Once done, a compact is generated. The quality of the compact may be influenced by many factors. These factors include powder type, particle size, composition, size distribution, and shape. The compact should likewise undergo sintering to fuse its particles effectively.
2. Sintering does not melt the compact and its particles.
Sintering is a process that generates a solid mass of material through metal powders. It involves pressure or heat. The heat provided to the metal powders does not necessarily melt them. Instead, it only increases their temperature just below their melting point, making sure that the metal powders can keep their intended properties as their particles fuse.
3. Density can affect the properties of the products.
One influential property of metal powders that should be considered throughout the powder metallurgy process is their density. Components that tend to be denser than others often have better properties. Density, after all, is directly connected to tensile strength, yield strength, and overall durability of metal powders. The porosity of metal powders can often indicate the density of components. To ensure that sintered components can perform optimally, their particles should not possess too much friction between them.
4. Necking is essential to minimise porosity.
Necking is a type of deformation wherein large amounts of strain can be found in a specific spot on powder materials. The decrease in the local cross-sectional area of the powder materials becomes the neck. As necking between metal particles grows, their spaces decrease significantly. And as porosity decreases, their density increases. Most manufacturers of sintered metals keep their metal particles in the necking state to effectively minimise porosity.
5. Powder metallurgy is environmentally friendly.
One more fact about powder metallurgy in general is it is environmentally friendly. It is a green manufacturing technique that can benefit not only the environment but also the manufacturers. One reason why it is eco-friendly is that almost all metals that undergo the powder metallurgy processes are converted into final products. Only 3% of the metal materials may be discarded in the end, minimising the number of waste generated by powder metallurgy.
Powder metallurgy is a service that PM Distributors can carry out for your needs. Contact us now if you want to obtain high-quality sintered products.
Metals are materials often used by a wide array of industries in producing parts and prototypes. The automotive industry, for instance, capitalises on engines, car chassis, and other components that are mostly made from metals. The electronics industry likewise uses metals in creating various parts of appliances, equipment pieces, and so on.
But not all metals boast similar qualities. Some metals can be stronger, while others may be more flexible than others. Given the differences in their properties, businesses should ensure that the metals they will maximise can make their operations successful.
Primary Qualities of Sintered Metal Parts
One type of metal that industries can utilise today is sintered metals. Sintered metals are materials generated through powder metallurgy. Powder metallurgy is a metal-forming process wherein metals are powdered, compacted, and exposed to temperatures below their melting points. This process can replace other metal fabrication processes that tend to be costly. Some processes powder metallurgy can replace are cutting, casting, and stamping.
The formation of a solid mass out of metal powders through heat and pressure is known as sintering. Sintered metal parts, after being exposed to temperatures below their melting points, are expected to boast properties that other metals may not possess.
A notable quality of sintered metal parts is they are cost-effective. Unlike other metal-forming processes, powder metallurgy does not generate too much material waste. This quality makes these parts cheaper to produce and obtain. Less material waste also means that these metals are eco-friendly. Sintered metal parts likewise have excellent surface finishes and good performance qualities. They can even have complex dimensions and shapes.
Heat Treating Process of Sintered Metals
Sintering is a heat treatment process that is often applied to compacted metal powders. It then allows the parts to become strong and long-lasting. But to make sintered metals more dependable, a lot of things should be considered whenever sintered parts are heat treated.
One of the things that should be considered when processing sintered metals is surface damage. Sintered metals are often designed to boast a net shape. They also avoid machining. And so, if they boast some surface damage, their acceptance may be reduced significantly.
Residual fluids are elements that must also be considered when processing sintered metals. Some metal parts may have had secondary operations before heat treatment and may boast residual fluids in their pores. The existence of these fluids may only affect their quality. These fluids may even lessen the part strength of the sintered metals.
Sintered metals often have a certain level of porosity on their parts. Hence, some quenchant used during their processing may only penetrate their pores. To prevent the infiltration of the quenchant, the sintered metals should be cleaned multiple times. Cleaning them can likewise reduce quenchant drag-out to the tempering process.
Now, some quenchants may be in the form of water. If industries maximise this quenchant, the sintered metals’ surface may be bombarded with some rust. Rust and other issues can be resolved by using quenchants with a corrosion inhibitor.
To acquire sintered metals, you can contact us at PM Distributors.